Usage:
Start By:
a. remove rear wheel bearings and Duo-Cone seals *
*This operation is in Power Train Disassembly And Assembly section.
1. Drain the oil from the hydraulic tank. The capacity of the tank is 166.5 liter (44 U.S. gal.).
2. Fasten a hoist to rear brake housing (1) as shown. Remove the 18 bolts that fasten the brake housing to axle housing (2). Remove the three nuts that fasten the brake housing to the axle housing. Remove the rear brake housing assembly from the axle housing. The weight of the rear brake housing assembly is 248 kg (550 lb).
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Support and piston assembly (3) is free to fall from axle housing (2). To prevent possible personal injury, be careful when the 12 bolts that fasten the support and piston assembly to the axle housing are removed. |
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3. Remove the 12 bolts that fasten the support onto the axle housing. Fasten a hoist to the support as shown. The weight of the support and piston assembly is 68 kg (150 lb).
4. Remove six O-ring seals (4) and O-ring seal (5) from the axle housing.
5. Remove 18 spring assemblies (6) from the support and piston assembly. Remove the support and piston assembly from the axle housing.
Install Service And Parking Brakes
1. Inspect the condition of all O-ring seals, and make replacements if necessary. Install six O-ring seals (3) and O-ring seal (1) on the axle housing.
2. Fasten a hoist to support and piston assembly (2) as shown, and put in position on the axle housing. The weight of the support and piston assembly is 68 kg (150 lb).
3. Install 18 spring assemblies (4) in the support. Put the support and piston assembly in position on axle housing (5), and install the 12 bolts that hold it. Tighten the bolts to a torque of 55 ± 7 N·m (40 ± 5 lb ft).
4. Install tooling (A) to hold hub (7) in position when brake housing assembly (6) is installed.
5. Fasten a hoist to the brake spring as shown, and put the brake housing assembly in position on the axle housing. Tighten the three nuts that fasten the brake housing to the axle housing. Tighten the three nuts evenly, one turn at a time until the nuts are tightened to a torque of 270 ± 40 N·m (200 ± 30 lb ft). The weight of the brake housing is 248 kg (550 lb).
6. Install the 18 bolts that fasten the brake housing to the axle housing. Tighten the bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
7. Fill the hydraulic tank with oil to the correct level. See the Operation And Maintenance Manual for further information.
8. Remove the air (bleed) from the brake system after the rear wheel bearings and Duo-Cone seals have been installed. See Testing And Adjusting, Form SENR5645, for the proper procedure.
End By:
a. install rear wheel bearings and Duo-Cone seals *
*This operation is in Power Train Disassembly And Assembly section.
Disassemble Service And Parking Brakes
Start By:
a. remove service and parking brake
1. Remove damper (1), 13 discs and 13 plates from housing (2).
2. Use a hoist and tool (A) as shown to remove hub (3) from housing (2). The weight of the hub is 32 kg (70 lb).
3. Remove O-ring seal (5) from hub (5).
4. Remove sixteen bolts (4) and washers that fasten plate (7) to the housing. Use a hoist and tool (B) to hold plate (7). Remove four nuts (6) evenly, one turn at a time until the plate is free from the housing.
5. Remove O-ring seal (8) from housing (2).
6. Use tooling (C) as shown to put service brake return springs (90 under compression. Remove the pins that hold guides (10) in the piston.
7. Remove four springs (9) and guides (10) from the pistons.
8. Use two 3/8 " - 16 NC forcing screws (12) to separate piston (11) and cylinder (13).
9. Remove two seals (14) and the two rubber ring seals from piston (11).
10. Remove four bolts (15) that fasten support (16) to cylinder (13).
11. Install two 3/8 " - 16 NC forged eyebolts in support (16), and fasten a hoist as shown. Remove the support from cylinder (13). The weight of the support assembly is 68 kg (150 lb). Remove the three seals from between the cylinder and the support.
12. Remove 12 bolts (17) that fasten housing (18) to support (16). Use two persons to remove the housing assembly from the support. The weight of the housing assembly is 30 kg (67 lb).
13. Remove three seals (19) from the support.
14. Put an alignment mark on piston (20) and housing (18) for assembly purposes. Put supports under the piston as shown. Use a soft hammer to push the housing out of the piston.
15. Remove two seals (21) and two rubber ring seals from housing (18).
Assemble Service And Parking Brakes
1. Inspect the condition of all seals, O-ring seals and rubber ring seals. Make replacements if necessary.
2. Install two rubber ring seals and two seals (2) on housing (1). Put a thin layer of SAE 30 oil on the seals. Put a support under piston (3) as shown, and install the housing in the piston. Be sure the alignment marks are aligned with each other.
3. Put three seals (5) in position on support (4).
4. Use two persons to put piston and housing assembly (1) in position on the support. The weight of the piston and housing assembly is 30 kg (67 lb).
5. Install the 12 bolts and washers that fasten the housing to the support. Tighten the bolts to a torque of 55 ± 7 N·m (40 ± 5 lb ft).
6. Install three seals (6) on support (4). Install the support assembly on the cylinder. The weight of the support assembly is 68 kg (150 lb).
7. Install four bolts (7) and washers that fasten the support to cylinder (8). Tighten the bolts to a torque of 55 ± 7 N·m (40 ± 5 lb ft).
8. Install two rubber ring seals and two seals (10) on piston (9). Put a thin layer of SAE 30 oil on the seals. Install the piston in cylinder (8).
9. Install four springs (12) on four guides (11). Put the springs and guides in position in piston (3) and piston (9).
10. Use tooling (A) to put spring (12) under compression. Install pin (13) in guide (11).
11. Install O-ring seal (15) on housing (14).
12. Install O-ring seal (17) on hub (16).
13. Put four nuts (19) in position in plate (18). Install the plate on the housing. Tighten the four nuts evenly, one turn at a time. Install 16 bolts (20) and washers that fasten the plate to the housing. Tighten the bolts to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
14. Use tool (B) to put hub (16) in position in plate (18). The weight of the hub is 32 kg (70 lb).
15. Install a plate in the housing. Put a thin layer of SAE 30 oil on each side of 13 discs (21). Install 13 discs (21) and 12 plates (22) in the housing. Start and stop with a disc.
16. Install damper assembly (23) in the housing with the facing material away from the disc.
End By:
a. install service and parking brake